Mk1 projects are always the funnest. looks good!
Merry Christmas! My lovely new wife says to me yesterday "So you were really going to have the car done by the wedding?"
Yesterday: Gave the passenger rear brake hose another shot. It's stuck on there pretty good and every vice grip and plier I have can't hold the rounded off nut. Finally after wasting another hour pulling on that, I decided to forget about it for a bit and do the driver side drum brake hardware.
Finished that in like 15 mins which certainly helped the confidence boost back up. While I was there, I also replaced the drivers side rear brake hose with ease. Just that damn passenger side giving me trouble..
Finally, I bolted up the brake booster and MC. Just have to get a drivers front brake line made up, install the new hoses/rotors/calipers/pads, and get that rear hose done and we'll have a rabbit that stops when you press the pedal!
Last edited by benjaminobscene; 02-01-2012 at 07:49 AM.
omg I actually worked on the rabbit last night!
I guess I've been a little distracted though. Right after Christmas I picked up a motorcycle in need of some refreshments and I guess it's been stealing all of my attention this past month. It's now to a point I'm happy with so the spotlight is back on the rabbit to get finished before show season.
So anyway, last night Jamie from Orchid Euro stopped by to help me with getting new brake lines bent and installed. The follow photos are courtesy of OE's fancy new instragram app.
We started off by pulling the motor out into the driveway for a much needed degreasing. It cleaned up ok. Still a bit of grime in the corners, but I'm not interested in pulling the whole thing apart and cleaning to perfection.
With the motor soaking we focused on getting the front brake lines bent and in place. Jamie did a great job tucking the lines nearly out of sight while I kept busy by rounding off yet another old brake line fitting.
I've gotten pretty good now at cutting stubborn things out of this car and even managed to save the little metal clip while sending the old brake line to hell where it belongs.
I now have a few new brackets to shave in the bay. I'm hoping this week I can get those, finish the brake lines, respray the bay, and get everything ready to finally drop the motor in.
Took the grinding wheel to some more brackets in the bay and laid a bit of filler to smooth. You can also sort of see the nice new brake lines. Gotta figure out what to do with those fuel lines...
Also got the new rotors, pads, and calipers installed. Anyone have an extra rotor securing screw laying around?
Moving along Ben
I usually run the fuel lines like they do stock Digi mk1's. The hardline stops just above the steering rack on the passenger side, and then slide rubber lines over, and clamp. Then run them to the fuel fitting on the engine.
Today: spent the afternoon sanding and respraying the bay. I was able to shave a few more brackets off the firewall, so I wanted to get those filled and painted in hopes of keeping the momentum going.
I went back out for a bit tonight and wrestled with that passenger rear brake line some more. After seeing how easy the Autozone pre-made lines are to use, I ended up just cutting it out.
Finally, I routed the rear lines to the master cylinder and cleaned the over spray off of them.
During my adventures under the car though, I found a third line that routes along with the fuel lines. It was wrapped up underneath the car, but looks like it's meant to come through the same opening. Any idea what this little guy is for?
Hey man that's a vacuum line that runs back to the fuel tank. I'm not sure if you'll need it or not but for my aba swap I removed the whole line and capped the bung on the tank. Getting the cap on sucked but is doable. as for your fuel lines, I'm not sure if you can see them in the picture but I took matt's advice on placement and used a tubing cutter to cut them down.
Thanks, Matt. I'll likely do the same then. Can I borrow your tubing cutter some time?
Tonight: FINALLY finished rebuilding the braking system. Using 2 pre-made Autozone lines and a union, I pieced together the rear passenger line and bent it into place. With the lines secured and snug, I greased the wheel bearings and slid the drums back on. Weeks ago I had hit them with some Chassis Black which really helped bring them back to life.
Did the nuts up, popped in some new cotter pins, and adjusted the parking brake. Wow, did that all just happen? Actual results? Now I just need to wait for an unsuspecting soul to wander into the garage to help me bleed the system.
With time left in the evening, I pulled the valve cover off the motor to replace the leaky gasket.
Everything looks ok in the head, but one spot on the cam has me a little concerned. Is this something to worry about or no big deal?
Anyway, I cleaned off the old gasket and put the new one in place along with the plastic cover.
While the valve cover is off, I also cleaned it out, sanded, and primed. Looking forward to having more fun with paint tomorrow
A few exciting (to me at least) updates with the car.
Ever since I installed the new manual steering rack, I've been pulling my hair out trying to figure out why the steering column joint would no longer reach the knob on the rack. For months I thought it was because I am using an early westy steering column with a late westy steering rack. After searching and searching for a longer U-Joint, I finally typed in the correct query terms here and found that my shaft could be collapsed.
I found the it's meant to be 22" long and after pulling everything apart again, my shaft came up a little short
Got that sorted and performed a quick zip-tie remedy for the lower bearing, and we're now able to turn the car!
This was the last piece of the puzzle that was keeping us from dropping the motor in. Hopefully I can source enough orange soda to convince Jamie to stop by with the engine lift sometime this weekend.
While I was in the garage I also started some other project areas that I've been putting off. I'm planning on having heat in the car, so tonight I cleaned up the blower, added a new strip of foam to seal it, and installed it into place.
Question: I picked up a used heater core a few months ago, but I'm not sure if I have the right size. How tight should it squeeze into the rectangular opening of the blower box thing? Right now, my heater core seems like it's too small... I'll grab a photo next time I'm out there.
Finally, I pulled the headlights out of the bucket to start bringing them back to life. They had some pretty gnarly surface rust, but luckily they are still solid enough to use. They cleaned up ok after some wire wheel action, but I'd still like to spray them with rust converter once I pick up another can.
On the heater core:
1. It should have a 1/2" of foam wrapped the whole way around it. Maybe that would fill the space?
2. Why are you using a used heatercore? They go bad, and a PITA to replace once everything's installed. I just checked and was surprised how much they cost (my cost is just under $50) but it's so easy to do it right at the moment. Maybe someone has a link to a cheaper source??
| œ Orchid Euro Importation œ |
Currently driving or working on too many cars...
| '93 Fox 16v - PVW | '99 Greenland Polo Diesel | '89 Rallye Golf | '83 Golf GTi RHD | '75 Swallowtail |
| '82 Caddy 1.9D | '85 VW LT Car Transporter | Mk2 Jetta Limo | '90 Jetta 8V | '96 VW LT35D | '03 SpintLT35 | '02 GTI 337 | '03 GTI 20v |
| '09 Aprilia RS125 | '81 Kawasaki AR80 | '59 NSU Quickly | '64 Honda Cub C65 + '65 C105 | Trek Emonda SLR9 | Trek Crockett 9 |
The opening between OE A/C equipped cars and non-a/c is different. A/C cars had a larger opening. If your car was originally an A/C equipped car (2 big square holes in the raintray one in the center and one on the passenger side) you'd need to make filler plate that screws into the large A/C opening, but has the opening for the Non-A/C box if you want it to fit properly.
Big day yesterday.
The motor went in surprisingly carefree. While Jamie was over we also tried to bleed the brakes, but with a completely empty system it was taking forever so we moved on to the motor. I also snapped off a bleeder valve which keeps things fun.
For now, all the other valves are open and gravity is doing its job.
I'm confused about the clutch cable grommet at the firewall. I think I have it figured out, but would greatly appreciate some reassurance.
In digging through my box of grommets, I pulled out a grommet with "clutch cable" scribbled on it. It looks exactly like item 34B. This grommet, however, is both too small to fit in the firewall hole and too small to slide over the end of the clutch cable.
After seeing this diagram, my hypothesis is that 34B is the grommet for an automatic transmission car (which my car was) and 34A is the appropriate grommet for the manual transmission cable.
Is the simple solution to just order a 34A?
yessir, sounds like you are missing the correct one. Any A1 manual trans car should have the same bushing. Could try one of the Mk1's at one of the local yards? Not sure if that part is obsolete or not
http://www.jimellisvwparts.com/produ...171721380.html for only $6. Shortys has been disappointing in the mk1 supply lately
I didn't have a whole lot of time this weekend, but tried to get as much done as possible in between yard work and running errands. Saturday morning, I added a few walls to the "paint booth" to try and minimize the mini blue dots accumulating on everything in the garage.
Also, while the sun was out warming everything up I laid out the nice new brown carpet courtesy of saddest6day66 to try and loosen it up after being folded in a cardboard box for years.
Back inside, I spent a lot of time sanding and cleaning out the rear part of the interior for some baby blue treatment. While that was drying, I got a little ahead of myself and test fit the carpet.
Fast forward to today, the paint was dry so pushed the car out into the sun and laid down some chassis black in the spare tire area. I'm very pleased with how this turned out. Almost looks like the black is there on purpose. Once that was dry, I started messing around with the battery location kit I ordered from Summit.
I then started to arrange some of the wiring but quickly got overwhelmed with that and decided to install the new driveshafts. Passenger side went in nice and smooth, but unfortunately I was unable to get the nut off the drivers side. The car has been rolling around on cut shafts so it's really hard to keep the wheel steady as I throw all 135lbs into the breaker bar..
Stuck again, I decided to fit the headlight buckets and threw the grill on for fun before wheeling it back into the garage for the day.